Thermally efficient cooking grate

ABSTRACT

A cooking grate for a grill is provided having substantially hollow rungs in fluid communication with each other and/or with a substantially hollow border to provide improved thermal management and more efficient heat transfer.

FIELD OF THE INVENTION

The present inventions relate to grilling assemblies having cookinggrates. More particularly, the present inventions relate to thermallyefficient cooking grates having substantially hollow rungs connected toand in fluid communication with each other and/or a border having asubstantially hollow, downwardly facing channel or chamber.

BACKGROUND OF THE INVENTION

There are a variety of known cooking grates used with charcoal, gas andelectric grills and grill type appliances. Typical grill assembliesinclude a lower firebox that houses the particular heat source. Thefirebox includes an upper ledge that serves to support a cooking grateabove the heat source. A lid, which may be hinged to the firebox, isalso provided to enclose the grate and firebox and forming a cookingchamber. The typical horizontal cross-sectional shape of the firebox isgenerally circular, square or rectangular, with the cooking grate havinga complimentary shape to sit on and be supported by the ledge of thefirebox.

Conventional cooking grates typically include a plurality of elongatedmembers or rungs that are usually parallel to one another and separatedby gaps or spaces to create a cooking surface. Support or cross membersmay also be provided which are transverse to or otherwise cross theplurality of elongated members or rungs. A frame that coincides with theshape of the firebox may also be provided to which the rungs andcross-member may be attached. Other conventional cooking grates areplate type members having slots and raised surfaces to support the foodto be cooked.

One type of conventional cooking grate is described in U.S. Pat. No.5,490,452, which is assigned to Weber-Stephen Products LLC. There, thegrate includes a number of elongate rods with openings between them. Therods are attached to a circular perimeter ring that coincides with theshape of the firebox. Support or cross members are also provided. Thecircular ring sits on the ledge of the firebox and supports the rungs toform the cooking surface. Another type of conventional grate is shown inU.S. Pat. No. 6,481,343, which provides for a rectangular plate typegrate having raised portions with openings. Other exemplary type gratesare shown and described in U.S. Pat. Nos. 7,810,484, 7,640,929 and7,373,875, all of which are also assigned to Weber-Stephen Products LLC.

Although effective, conventional grates are slow to respond to thermalchanges, largely because of the solid nature of the rungs and theirinability to thermally communicate with one another. This may result in,among other things, ineffective searing of food. Solid rungs may alsoresult in excess smoke and grease build-up depending upon the type ofgrill. Therefore, there is a need for cooking grates that provide betterthermal management and more efficient heat transfer. The presentinventions and the various embodiments thereof achieve one or all ofthese goals as well as others.

SUMMARY OF THE INVENTION

The present inventions preserve the advantages of known cooking gratesand also provide new features, objects and advantages that aresummarized herein.

In a preferred embodiment of the present invention, a grill assembly isprovided that includes a firebox having a top, a bottom, a front and aback, with the bottom of the firebox having a generally central opening.A heat source located near the bottom of the firebox is also provided.The preferred embodiment provides at least one cooking grate removablysupported by the firebox above and adjacent to the heat source, thecooking grate defined by at least a first border portion and a secondborder portion which may be supported by the firebox, the borderportions having a substantially hollow, downwardly facing interiorchannel. A plurality of substantially hollow, spaced apart rungs areprovided, each end of which is joined to and in fluid communication withthe substantially hollow interior of the first and second borderportions. In a preferred embodiment, each rung of the grill assembly hasa length, two ends, a bottom surface and a cross-sectional shape, thebottom surface having a downwardly facing, concave shape forming asubstantially hollow channel along at least a substantial portion of thebottom surface of the length of each rung. The cooking grate may furtherinclude at least one transverse cross member having a substantiallyhollow, downwardly facing interior channel which is in fluidcommunication with said rungs. Also in a preferred embodiment, theborder portions include an upper surface connected to an outer legwherein the upper surface and outer leg form a substantially open,downwardly facing channel. The preferred grill assembly may provide aplurality of grate sections (e.g., a right grate piece and a left gratepiece) that together form the cooking surface of the grill. Thesubstantially hollow border portion of each grate piece may furtherinclude a third or fourth border portion interconnecting the first andsecond border portions. In a preferred embodiment, the transversesupport member is in fluid communication with the third or fourth borderportions. The preferred border portions may include an inner leg and anouter leg. In an alternative preferred embodiment, the bottom surface ofthe rungs include bottom edges that taper along the length from one, orboth ends toward the center of the length of the rung.

The present inventions also provide for a grill assembly having afirebox with a front, a back, two sides and a bottom, the bottom havinga generally central opening and an upper portion of the firebox having aledge, as well as a heat source located with the firebox and below theledge. A cooking grate removably supported on the ledge of the firebox,the cooking grate including a plurality of spaced apart rungs withspaces therebetween, the rungs having a length, a front end and a rearend, a bottom surface and a cross-sectional shape, the cross-sectionalshape of the bottom surface forming a substantially open and downwardlyfacing, concave channel along at least a portion of the length of therungs are provided. The front end of the rungs are joined to and influid communication with a substantially hollow front border portion andthe rear end of the rungs are joined to and in fluid communication witha rear border portion, both border portions capable of resting on theledge of the firebox. At least one substantially hollow side borderportion which is connected to and in fluid communication with the frontand rear border portions may also be included. Where the front borderportion joins the side border portion and where the rear border portionjoins the side border portion may be chamfered to properly sit on andalign with the ledge of the firebox. In another preferred embodiment,the length of the rung includes two side surfaces, the side surfacesincreasing in depth from each end of the rung to a center of the rung.Each border portion may additionally include a cross-section having agenerally triangular configuration and a substantially hollow interiorchamber, as well as an upper surface that forms a downwardly slopingsurface from an outside edge to a center of the firebox.

A cooking grate for use on a grill, the cooking grate having a first endand a second end is further provided. The cooking grate includes asubstantially hollow border having at least a first border portion and asecond border portion, a plurality of spaced apart rungs having spacestherebetween, each rung having a first end, a second end, a top surfaceand a bottoms surface, the bottom surface forming a downwardly facing,concave shape forming a substantially hollow channel along a substantialportion of the rungs from the first end to the second end. Moreover, thefirst end of each rung is joined to the at least first border portion,and the second end of each rung joined to the second border portion,respectively, such that the substantially hollow channel of the rungs isin fluid communication with the substantially hollow channel of eachborder portion. A third substantially hollow border portion connected toand in fluid communication with the first and second border portions mayalso be provided. Each preferred border portion may include an uppersurface and outside edge, wherein the upper surface slopes downwardlyfrom the outside edge to an inner portion. In addition, the rungs mayinclude side surfaces, the side surfaces increasing in height from thefirst end and the second end toward a center of the rungs. In stillanother embodiment, a first, a second and third border portions areprovided forming an edge along three sides of said grate, each of whichis attached to and in fluid communication with the adjacent borderportion. In this embodiment, two grates may be provided, each having atleast three border portions adjacent to the ledge of the firebox tocollectively form the cooking surface. In addition, each border portionmay include a substantially downwardly facing opening or channel alongthe bottom.

In addition, at least one cross member having two ends and a bottomsurface forming a substantially hollow, downwardly facing channel, atleast one end of the cross member joined to and in fluid communicationwith said third border portion may be provided, wherein the at least onecross member is in fluid communication with said rungs. In yet anotherembodiment, a cooking grate for use on a grill is provided having aplurality of spaced apart rungs, each rung having a top surface and abottom surface, the bottom surface forming a downwardly facing,substantially hollow channel; and at least one cross member, the crossmember having a top surface and a bottom surface, the bottom surfaceforming a downwardly facing, substantially hollow channel; wherein thehollow channels of the rungs are in fluid communication with the hollowchannel of the cross member.

Accordingly, it is an object of the present invention to provide acooking grate that promotes better thermal management and heat transfer.

It is another object of the present invention to provide a cooking gratethat includes substantially hollow or downwardly facing channel shapedrungs that are in fluid communication with each other.

It is an additional object of the present invention to provide a cookinggrate having a plurality of substantially hollow or downwardly facingchannel shaped rungs that are in fluid communication with each other anda substantially hollow, downwardly facing cross member.

It is also an object of the present invention to provide a cooking gratehaving a border forming a downwardly facing concave channel to which therungs are joined and are in fluid communication therewith.

It is a further object of the present invention to provide a cookinggrate having a substantially hollow border which may be in fluidcommunication with the previously mentioned hollow rungs and/or crossmember.

It is still another object of the present invention to provide a cookinggrate having substantially hollow or channel shaped rungs which are influid (air) communication with the substantially hollow border or aborder having a substantially downwardly facing channel.

It is still a further object of the present invention to provide acooking grate having substantially hollow or channel shaped rungs withspaces therebetween wherein the rungs are positioned to coincide withand/or be positioned above the heat source.

It is still an additional object of the present invention to provide acooking grate having substantially hollow or channel shaped rungs havinga tapered bottom surface that slopes downward toward the center of thefirebox.

Still yet another object of the present invention is to provide acooking grate having feet attached to the underside of the substantiallyhollow border.

Inventor's Definition of the Terms

The following terms which may be used in the various claims and/orspecification of this patent are intended to have their broadest meaningconsistent with the requirements of law:

“Grill assembly” as used herein includes the components of a typicalgrill such as a firebox, legs or a stand supporting the firebox, a heatsource, a cooking grate and a lid (that may be hinged to the firebox).Grill assembly may also include grills without legs or a cart, such ascountertop or “drop-in” units with a firebox, heat source, cookinggrate, lid and the like.

“Heat source” as used herein shall mean electric (i.e., an electricheating element), gas (i.e., natural, propane or other gas delivered viaburner tubes) and/or charcoal (i.e., charcoal, coal, wood or othercombustive materials).

“Firebox” as used herein shall mean the lower enclosure of a grill thathouses and/or supports the heat source and the cooking grate. One ofskill in the art may also refer to the firebox as a cookbox.

“Cooking chamber” as used herein refers to the portion of the grillassembly generally above the grate in the firebox and below the lid whenin a closed position on the firebox.

“Ledge” as used herein shall mean any structure capable of supporting acooking grate in the firebox to form a cooking surface on the top of thecooking grate. Such structures may include tabs, a rim or a shelf aroundall or a portion of the interior of the firebox and/or clip or hook typemembers. Ledge as used herein may also include the firebox itself inembodiments where the cooking grate is part of or integral with thefirebox.

Where alternative meanings are possible, in either the specification orclaims, the broadest meaning is intended consistent with theunderstanding of those of ordinary skill in the art. All words used inthe claims are intended to be used in the normal, customary usage ofgrammar, the trade and the English language.

BRIEF DESCRIPTION OF THE DRAWINGS

The stated and unstated objects, features and advantages of the presentinventions (sometimes used in the singular, but not excluding theplural) will become apparent from the following descriptions anddrawings, wherein like reference numerals represent like elements in thevarious views, and in which:

FIG. 1 is a top perspective view of a preferred embodiment of a grate ofthe present invention shown in conjunction with a typical firebox andrepresentative electric heating element, as well as two grate sectionsforming the cooking surface.

FIG. 2 is a bottom perspective view of a preferred grate of the presentinvention showing the generally downward facing, hollow or channelshaped rungs, a generally hollow shaped cross member, and the rungs andcross member joined to and in fluid communication with a border having asubstantially hollow, downwardly facing concave channel on its bottomsurface.

FIG. 2A is a bottom plan view of a preferred alternative embodiment ofthe grate of the present invention showing the hollow channels on thebottom surface of the rungs in fluid communication with the hollowchannels on the bottom surface of a cross member, all in fluidcommunication with each other.

FIG. 2B is a bottom perspective view of the preferred alternativeembodiment of the grate of FIG. 2A.

FIG. 3 is a cross-sectional view of the preferred grate of the presentinvention taken along line 3-3 of FIG. 1 and showing a preferred border.

FIG. 3A is a cross-sectional view of a preferred grate of the presentinvention having an alternative three sided border forming a generallyhollow interior channel or plenum.

FIG. 3B is a cross-sectional view of the alternative preferred border ofFIG. 3A of the present invention.

FIG. 4 is a bottom perspective view of a portion of an alternativeembodiment of a grate section of the present invention, the embodimenthaving rungs that are tapered on their bottom surface and joined to theborder embodiment of FIG. 3.

FIG. 5 is a front plan view of the inside edge of a preferredalternative embodiment of a grate section of the present inventionshowing tapered rungs that have their largest height in the center ofthe rungs.

FIG. 6 is a cross-sectional view of the preferred alternative embodimentof the grate rungs of the present invention taking along line 6-6 ofFIG. 4 showing the tapered rungs.

FIG. 6A is a cross-sectional view of the alternative rungs of FIG. 4 andthe alternative border of FIGS. 3A and 3B of the present invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Set forth below is a description of what is currently believed to be thepreferred embodiments or best representative examples of the inventionsclaimed. Future and present alternatives and modifications to theembodiments and preferred embodiments are contemplated. Any alternativesor modifications which make insubstantial changes in function, purpose,structure or result are intended to be covered by the claims of thispatent.

A preferred cooking grate of the present invention is shown generally as40 in FIG. 1. Cooking grate 40 may be used on a variety of grillassemblies having a variety of shapes and heat sources. A generallyrectangular firebox is shown as 10 in FIG. 1. It will be understood bythose of skill in the art that firebox 10 may be other shapes, such asgenerally square or circular. In addition, in a preferred embodiment ofthe present invention, two cooking grates 40, which also may be referredto herein as cooking grate sections 40, are provided, one for the leftside of the firebox and one for the right side of the firebox 10. As aresult, the terms cooking grate and cooking grate sections are usedinterchangeably in this patent. In the preferred embodiment of FIG. 1,cooking grates 40 (i.e., the two cooking grate sections 40) are a mirrorimage of each other. It will be understood by those of skill in the artthat a cooking surface 41 formed by the cooking grates 40 of the presentinvention may be formed of a single grate section 40 or grate 40 or morethan two grate sections 40. In addition, a representative electricheating element 12 is shown as the heat source in a preferredembodiment. Those of skill in the art will further understand that thecooking grates of the present invention may be used with grillassemblies having other heat sources.

Representative firebox 10 includes a first (or front) wall 17, a second(or rear) wall 16, a third (or right) side wall 14 and a fourth (orleft) side wall 15. Bottom wall 18 includes an opening 19 where greaseor other cooking debris may be discharged from the firebox 10 andcollected in a drip pan (not shown) for purposes of cleaning or removal.A ledge 20, as broadly defined herein, is positioned along the interiorupper portion of firebox 10 and supports grate or grate sections 40 in agenerally horizontal position below rim 21 of firebox 10. It will beunderstood by those of skill in the art that a datum or other locatingmember may be provided (not shown) on ledge 20 or elsewhere on thefirebox 10 to provide a locating feature for placement of grate sections40 (particularly in embodiments where two or more grate sections 40 areused) so that the user may properly install the grates 40.Alternatively, the right and left grate sections 40 may not besymmetrical, such that they may be placed on ledge 20 only on the properside. As previously indicated, when grate 40 is referenced herein, itwill be understood that a cooking surface 41 may include a single grate40 or two or more grate sections 40.

A preferred embodiment of grate 40 may be seen by reference to FIGS. 1,2 and 3. Grate 40 includes a plurality of spaced apart and substantiallyhollow or open rungs 42. Between each rung is a gap or open space 43. Ina preferred embodiment, the rungs 42 are parallel to one another. Itwill be understood that other rung 42 configurations are contemplated,such as diamond shaped or criss-crossed rungs 42 (not shown). Each rung42 has a length (FIGS. 1 and 2) and a cross-sectional shape (FIG. 3). Ina preferred embodiment, the length of the rungs 42 extends from first orfront 17 to second or back 16 of firebox 10. Although preferred, it willbe understood that the rungs 42 of grate 40 of the present inventions(when parallel) may have a length from a second side 14 to a third side15 of firebox 10. Accordingly, in this patent, front, back, right andleft are used for illustrative purposes only. In the preferredembodiment, the front or first end 44 and back or second end 45 of eachrung 42 is attached to (or otherwise joined with) and is in fluidcommunication with a substantially hollow border 60 as hereinafterdescribed. Each rung 42 includes a top surface 46 and a bottom surface47. The top surface 46 of the plurality of rungs 42 collectively formthe cooking surface 41 upon which food items are placed.

A preferred cross-sectional shape of rungs 42 in a preferred embodimentcan be seen in FIG. 3. The underside of a preferred half grate section40 and preferred rungs 42 may best be seen by reference to FIG. 2. Asshown in FIGS. 1 and 3, the top surface 46 is flattened to support thefood to be cooked. It will be understood by those of skill in the artthat top surface 46 may take other shapes consistent with the presentinventions. In a preferred embodiment, bottom surface 47 forms asubstantially hollow, downwardly oriented concave channel. It will beunderstood by those of skill in the art that other substantially open orchannel-like shapes of bottom surface 47 may be used consistent with thepresent inventions. Alternatively, a rung 42 formed from a hollow tubehaving a substantially hollow interior may also be used. Each rung 42includes side surfaces 49 which terminate in two bottom edges 48. Inthis manner, a preferred substantially hollow channel is formed on thebottom surface 47 of rungs 42 to trap hot air rising from the heatsource and to provide increased surface area to absorb radiant heatenergy. In addition, hot air is allowed to flow along the substantiallyhollow channel formed on lower surface 47 to other parts of rung 42,cross member 50 and/or border 60 as hereinafter described.

A transverse cross support member 50 may also be provided to helpstrengthen grate 40 and to support rungs 42. Cross member 50 may alsoaid in fluid communication between the rungs 42 and/or border 60. In apreferred embodiment, a single cross member 50 is provided and has thesame general cross-sectional shape as rungs 42. Specifically, crossmember 50 has a top surface 51, bottom surface 52, side surfaces 54 andbottom edges 53. As shown in FIG. 2, a substantially hollow channel isformed on the bottom surface 52 to function to trap and/or transfer hotair and provide increased surface area like the bottom surface 47 ofrungs 42 as discussed above. As shown in FIG. 2, the side surfaces 54 ofcross member 50 interrupt the channel formed in the concave bottomsurface 47 of rungs 42. In other contemplated embodiments (see e.g.,FIGS. 2A and 2B), cross member 50 may be configured so that the channelon bottom surface 47 of rung 42 runs the entire length of rung 42. Inaddition, top surface 51 may form part of the cooking surface 41 or itmay be positioned below the top surface 46 or rung 42 so as not to bepart of cooking surface 41 as shown. In the preferred embodiment, crossmember 50 is approximately at the center 39 of the length of rungs 42.In embodiments that have more than one cross member 50, such members maynot be located at the center 39 of rungs 42.

FIGS. 2A and 2B show alternative embodiments of the rungs 42 and crossmember 50 of the present invention. In this embodiment, the sidesurfaces 54 of cross member 50 do not interrupt the channel on thebottom surface 47 of rungs 42. In other words, the substantially open,downwardly facing channel formed on the bottom surface 47 of rungs 42 isin fluid communication with the substantially hollow channel formed onbottom surface 52 of cross member 50. In this manner, the rungs 42 andcross member 50 are in fluid communication with each other. Thisalternative configuration may be used with a border 60 (or borderportion) as hereinafter described, but is particularly useful inembodiments of grate 40 of the present invention that do not include aborder 60.

A substantially hollow border 60 is also provided, into which the ends44 and 45 of rung 42 are joined. As indicated, in a preferredembodiment, two grate sections 40 are used to form cooking surface 41.In this embodiment, border 60 includes a front (or first) border portion61 adjacent to front wall 17, a rear (or second) border portion 62adjacent to rear wall 16 and a side (or third) border portion 63adjacent to either side wall 14 or side wall 15 of firebox 10. In suchan embodiment, one end of cross member 50 is joined to, and preferablyin fluid communication with, side (or third) border portion 63. In thisembodiment, there is only one side border portion 63 on each cookinggrate piece 40, since the two center edges of right and left grate 40without a side border portion 63 come together in the center of firebox10 (see generally, FIG. 1).

It will be understood by those of skill in the art that the presentinventions contemplate different border 60 arrangements. For example, inthe embodiment of FIG. 1, it is possible to have only a front (or first)border portion 61 and a rear (or second) border portion 62. In anembodiment where only one cooking grate 40 is used, a border 60 aroundthe entire perimeter of grate 40 and ledge 20 may be provided. Also asused herein with respect to grate 40 and border portions 61, 62 and 63,the first 61 and second 62 border portions are opposite each other. Thethird 63 and any additional border portions are adjacent to and/orinterconnect the first 61 and second 62 border portions. In other words,first and second border portions 61, 62 do not have to coincide with thefront and rear of the firebox 10 or grate 40. This is because, amongother reasons, the grate 40 may take a variety of configurations (e.g.,non-parallel rungs 42 or rungs 42 going from side to side of firebox10), as well as different border 60 configurations (e.g., two, three orfour border portions).

As shown in a preferred embodiment of FIG. 1, when the two grateportions 40 are used, front (first) 61, rear (second) 62 and side(third) 63 border portions 60 are preferred and form the edges of grateportions 40 which are in turn supported by ledge 20 of firebox 10. And,as indicated above, embodiments of grate 40 are contemplated where thereis no substantially hollow border 60. In such an embodiment, rungs 42may be supported by ledge 20 of firebox 10. A ring or similar solidstructure may also be used in the embodiment without a substantiallyhollow border 60. Still other embodiments are also contemplated as willbe understood by those of skill in the art.

Returning to a preferred embodiment of border 60 as shown in FIGS. 1, 2and 3, the border 60 coincides with the perimeter of ledge 20 of firebox10 when both grate pieces 40 are installed. In a preferred embodiment,front or first border portion 61, side or third border portion 63 andrear or second border portion 62 have a substantially hollow interior ashereinafter described. As previously indicated, front, side and rearborder portions do not have to coincide with the front, side and rear ofthe firebox 10 and the inventions are not so limited. The preferredembodiment front border portion 61 is connected at one end to sideborder portion 63 and rear border portion 62 is also connected at oneend to side border portion 63, preferably forming a generally continuousand hollow border 60. End caps 64 are provided to close off front borderportion 61 and rear border portion 62 in the center of the firebox 10 inembodiments where two grate pieces 40 are used as shown in FIG. 1.

The preferred cross-sectional configuration of border 60 (and/or borderportions 61, 62 and 63) may best be seen by reference to FIGS. 2 and 3.Border 60 (i.e., if provided, the border portions 61, 62 and 63) includean upper surface 65 that slopes downwardly from an outside edge 66 ofborder 60 toward the center of firebox 10. In this manner, greasemanagement is improved in that any grease that is deposited on uppersurface 65 during cooking may flow down the angular upper surface 65into the firebox. A generally vertical outer leg 67 is provided andextends downwardly from outer edge 66. Upper surface 65 and outer leg 67form a downwardly facing, substantially hollow or open channel orchamber 70. Channel 70 permits the flow and transfer of heat between andaround border 60 (if provided), hollow rungs 42 and hollow cross member50 (if provided).

Rungs 42 join border 60 as shown in FIG. 2. Specifically, the hollowchannel formed on the bottom surface 47 of each rung end 44 and 45 leadsto the interior of hollow channel or chamber 70 of border 60. The topsurface of each rung 42 is connected to angular upper surface 65 ofborder 60. Similarly, the end of cross member 50 adjacent to sideportion 63 of border 60 is formed to join to side portion 63 andpreferably, is in fluid communication therewith. In this manner, thechannel or bottom surface 47 of rungs 42 and the channel in bottomsurface 52 of cross member 50 are in fluid communication with hollowchannel or chamber 70 of border 60. As a result, heat may be transferredbetween the channels 47 and 52 and hollow chamber 70, as well as aroundthe hollow chamber 70 of the provided border portions 60.

These preferred arrangements provide for more even heat distribution atthe cooking surface 41 because the hot air moves around grate 40 morequickly than just heat conduction within the bulk of the grate. Inaddition, the thermal mass provided by the hollow grate 40 and crossmember 50 (if so equipped) provide for faster heat recovery time, suchas when food is flipped during cooking, providing a better sear. Inother words, hollow rungs 42, hollow cross member 50 and hollow border60 permit faster heating.

An alternative embodiment of border 60 is shown in FIGS. 2A and 3B. Inthis embodiment, border 60 includes an inner leg 68 which extends towardouter leg 67. Inner leg 68 and outer leg 67 terminate in spaced apartends 69. In this manner, a substantially hollow chamber 70 is formed inthe interior of border 60 having an open bottom 71.

It will be understood by those of skill in the art and from the figuresthat preferred grate 40 is manufactured by casting. It will beappreciated, however, that the present inventions may be formed by othermeans. For example, individual rungs 42 formed of hollow tubular orchannel members may be welded or otherwise attached to border 60 suchthat the hollow interior or channel is in fluid communication with thesubstantially hollow border 60.

Similarly, border 60 may be constructed from a variety of materials thatare able to endure the high heat of a grill environment. In addition,border 60 does not have to take the generally angular shape of thepreferred embodiment as shown, for example, in FIG. 3. For example, thecross-sectional shape of border 60 may be rectangular or triangular(FIGS. 3A and 3B) as opposed to the generally angular cross-section asshown in the preferred embodiment of FIGS. 2, 3, 4 and 6. Further,although the opened bottom 71 of border 60 is preferred because of heattransfer considerations, a closed bottom 71 may also be used consistentwith the present inventions.

In the preferred embodiment, a plurality of feet 80 are attached to thebottom of border 60. Feet 80 are located near but within the edge ofborder 60 and are sized and positioned to rest on ledge 20 of firebox10. The feet 80 keep border 60 from contacting ledge 20 around theentire perimeter of ledge 20 and border 60. This aids grease managementand prevents grease from being trapped. Similarly, feet 80 space theopen bottom 71 of border 60 from abutting ledge 20. This keeps the openbottom 71 of hollow chamber 70 open so that heat is better and morefreely transferred around grate 40.

An alternative preferred embodiment of the rungs 42 of the presentinventions is shown in FIGS. 4, 5, 6 and 6A. In this embodiment, therungs 42 are tapered from the outside edges to the center of the firebox10. More specifically, rungs 42 in the alternative preferred embodimentinclude a top surface 46 and a bottom surface 47 forming a substantiallyhollow channel. Bottom edges 48 and tapered side surfaces 49 ¹ areprovided. As best shown in FIG. 5, the side surfaces 49 ¹ taper alongthe length of rung 42 from the end that joins with generally hollowborder 60 and the approximate center 39 of tapered rung 42. In all otheraspects, the description of this alternative embodiment is the same asthe earlier description of the preferred embodiment. However, thealternative embodiment having tapered rungs 42 ¹ is particularly usefulfor grease management. For example, grease on rung 42 ¹ may be directedto the center 39 by running down the bottom edges 48 of the tapered rung42 ¹ toward the center of firebox 10. Similar heat transfer and thermalmanagement of both embodiments is achieved by, among other things, theabove described substantially hollow border 60 and substantially hollowbottom 47 of rungs 42 and 42 ¹. It will be understood by those of skillin the art that other configurations are possible and are contemplatedby this patent.

The above description is not intended to limit the meaning of the wordsused in or the scope of the following claims that define the invention.Rather, it is contemplated that future modifications in structure,function or result will exist that are not substantial changes and thatall such insubstantial changes in what is claimed are intended to becovered by the claims. Thus, while preferred embodiments of the presentinventions have been illustrated and described, it will be understoodthat changes and modifications can be made without departing from theclaimed invention. In addition, although the term “claimed invention” or“present invention” is sometimes used herein in the singular, it will beunderstood that there are a plurality of inventions as described andclaimed.

Various features of the present inventions are set forth in thefollowing claims.

What is claimed is:
 1. A grill assembly comprising: a firebox having atop, a bottom, a front and a back, the bottom of the firebox having agenerally central opening; a heat source located near the bottom of thefirebox; at least one cooking grate removably supported by the firebox,above and adjacent to the heat source, the cooking grate defined by atleast a first border portion and a second border portion supported bythe firebox, the border portions having a substantially hollow,downwardly facing interior channel, and wherein a plurality ofsubstantially hollow, spaced apart rungs are provided, each end of whichis joined to and in fluid communication with the substantially hollowinterior of the first and second border portions.
 2. The grill assemblyof claim 1 wherein each rung has a length, two ends, a bottom surfaceand a cross-sectional shape, the bottom surface of the cross-sectionalshape being a downwardly facing, concave shape forming a substantiallyhollow channel along the bottom surface of at least a substantialportion of the length of each rung.
 3. The grill assembly of claim 2wherein the cooking grate includes at least one transverse cross memberhaving a bottom surface with a substantially hollow, downwardly facinginterior channel which is in fluid communication with said rungs.
 4. Thegrill assembly of claim 3 wherein the border portions include an uppersurface connected to an outer leg wherein the upper surface and outerleg form a substantially open, downwardly facing channel.
 5. The grillassembly of claim 4 wherein a plurality of grate sections are providedto form a cooking surface of the grill.
 6. The grill assembly of claim 5wherein the border of each grate section includes an additional borderportion interconnecting the first and second border portions.
 7. Thegrill assembly of claim 6 wherein said cross member is in fluidcommunication with said additional border portion.
 8. The grill assemblyof claim 4 wherein the border portions include an inner leg and/or anouter leg.
 9. The grill assembly of claim 2 wherein the bottom surfaceof the rungs include bottom edges that taper along the length from a oneend and the other end toward a center of the length of the rungs.
 10. Agrill assembly comprising: a firebox having a front, a back, two sidesand a bottom, the bottom of the firebox having a generally centralopening and an upper portion of the firebox having a ledge; a heatsource located with the firebox below the ledge; a cooking grateremovably supported on the ledge of the firebox, the cooking grateincluding a plurality of spaced apart rungs with spaces therebetween,the rungs having a length, a front end and a rear end, a bottom surfaceand a cross-sectional shape, the cross-sectional shape of the bottomsurface forming a substantially open or downwardly facing, concavechannel along at least a portion of the length of the rungs, the frontend of the rungs are joined to and in fluid communication with asubstantially hollow front border portion and the rear end of the rungsare joined to and in fluid communication with a rear border portion. 11.The grill assembly of claim 10 having at least one substantially hollowside border portion which is connected to and in fluid communicationwith the front and rear border portions.
 12. The grill assembly of claim10 wherein the length of the rung includes two side surfaces, the sidesurfaces increasing in depth from each end of the rung to a center ofthe rung.
 13. The grill assembly of claim 11 wherein the border portionsinclude an upper surface that forms a downwardly sloping surface from anoutside edge of the border portion toward a center of the firebox. 14.The grill assembly of claim 12 wherein each border portion has agenerally triangular cross-sectional shape and a substantially open,downwardly facing channel or hollow interior chamber.
 15. A cookinggrate for use on a grill, the cooking grate having a first end and asecond end, the cooking grate comprising: a substantially hollow borderhaving at least a first border portion and a second border portion; aplurality of spaced apart rungs having spaces therebetween, each runghaving a first end, a second end, a top surface, and a bottom surface,the bottom surface forming a downwardly facing, concave shape forming asubstantially hollow channel on a substantial portion of the rungs fromthe first end to the second end; and further, wherein the first andsecond end of each rung is joined to the first and second borderportions respectively, such that the substantially hollow channel of therungs is in fluid communication with the substantially hollow borderportion.
 16. The cooking grate of claim 15 wherein a substantiallyhollow third border portion connected to and in fluid communication withthe first and second border portions is provided.
 17. The cooking grateof claim 16 wherein each border portion includes an upper surface andoutside edge, wherein the upper surface slopes downwardly from theoutside edge to an inner portion.
 18. The cooking grate of claim 16wherein the rungs include side surfaces, the side surfaces increasing inwidth from the first end and the second end toward a center of therungs.
 19. The cooking grate of claim 16 wherein a first, a second, anda third border portions are provided forming an edge along three sidesof said grate, each of which is attached to and in fluid communicationwith the adjacent border portion.
 20. The cooking grate of claim 17wherein each border portion includes a downwardly facing opening orchannel.
 21. The cooking grate of claim 16 wherein at least one crossmember, having two ends and a bottom surface forming a substantiallyhollow, downwardly facing channel, at least one end of the cross memberjoined to and in fluid communication with said third border portion. 22.The cooking grate of claim 21 wherein the at least one cross member isin fluid communication with said rungs.
 23. A cooking grate for use on agrill, the cooking grate comprising: a plurality of spaced apart rungs,each rung having a top surface and a bottom surface, the bottom surfaceforming a downwardly facing, substantially hollow channel; and at leastone cross member, the cross member having a top surface and a bottomsurface, the bottom surface forming a downwardly facing, substantiallyhollow channel wherein the hollow channel of the rungs is in fluidcommunication with the hollow channel of the cross member.